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IAME Parilla X30 125cc RL, Overhaul Manual

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28/09/05                                                                                                                                     MAN-044 /A 

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OVERHAUL MANUAL

 

Summary of Contents for Parilla X30 125cc RL

Page 1: ...28 09 05 MAN 044 A 1 OVERHAUL MANUAL ...

Page 2: ...CRANKSHAFT ASSEMBLY 12 3 PARILLA X30 125cc RL TaG ENGINE ASSEMBLY 15 ATTACHMENTS FASTENER TORQUE VALUES CROSS PATTERN LOCKING ORDER ON CRANKCASE MAIN PRESCRIPTIONS CON ROD BIG AND SMALL END BEARING TOLERANCES GEAR INSTALLATION RECOMMENDATIONS LIST OF OVERHAUL TOOLS Table for wear evaluation on Bearings Halfcrankshafts BENCH ENGINE FIXING TOOL Drawing ...

Page 3: ...PLUG see Fig 1 14mm socket wrench TILT THE ENGINE TO DISCHARGE OIL see Fig 2 2 FIX THE ENGINE ON THE BENCH VICE SCREW ON N 2 SCREWS M8x60 ON THE CRANKCASE BENCH TOOL see attached drawing 3 REMOVE THE EXHAUST HEADER UNSCREW N 2 NUTS M8 see Fig 3 13mm SOCKET WRENCH REMOVE N 2 WASHERS REMOVE THE EXHAUST GASKET Fig 1 Fig 2 Fig 3 ...

Page 4: ...m ALLEN WRENCH T TYPE REMOVE SPARKPLUG AND INSTALL THE THE PISTON FITTING P N 10271 TO PREVENT THE CRANKSHAFT FROM TURNING see Fig 5 REMOVE THE NUT M10 AND WASHER see Fig 6 17mm SOCKET WRENCH EXTRACT THE ROTOR see Fig 7 USE A SCREWDRIVER IF NECESSARY REMOVE KEY FROM SHAFT Fig 4 Fig 5 Fig 6 Fig 7 ...

Page 5: ...INING RINGS FROM THE CRANKSHAFT AND BALANCE SHAFT see Fig 10 PLIERS FOR RETAINING RINGS REMOVE GEAR ON THE CRANKSHAFT see Fig 11 ATTENTION MARK THE GEAR FOR IDENTIFICATION WHEN REASSEMBLING NOTE IN THE ENGINES MNUFACTURED AFTER SEPTEMBER 05 THE FIXING OF THE GEAR ON THE CRANKSHAFT IS MADE BY A SPACER WITH AN OR WHICH IS PUSHED AGAINST GEAR BY THE IGNITION ROTOR see drawing Fig 8 Fig 9 Fig 10 Fig 1...

Page 6: ...ENCH T TYPE REMOVE STARTER see Fig 14 NOTE IN THE ENGINES MNUFACTURED AFTER SEPTEMBER 05 THE STARTER CAN ALSO BE REMOVED WITHOUT TAKING AWAY THE GEARS COVER BUT SIMPLY BY REMOVING THE CLAMP OF THE COVER see drawing 8 REMOVE CLUTCH DISCONNECT THE GROUND CABLE FROM THE CRANKCASE UNSCREW THE ALLEN SCREW M6x12 see Fig 15 5mm ALLEN WRENCH T TYPE Fig 12 Fig 13 Fig 14 Fig 15 ...

Page 7: ...1 REMOVE OUTER WASHER CLUTCH DRUM ROLLER CAGE AND INNER WASHER REMOVE THE PISTON STOP TOOL AND WITH THE CLUTCH LOCKING WRENCH P N 10270 REMOVE THE LOCKING NUT M20 FROM CLUTCH BODY see Fig 18 30 mm HEXAGON RING WRENCH ATTENTION TURN CLOCKWISE AS NUT HAS LEFT THREAD REMOVE CLUTCH BODY AND STARTING RING FROM THE CRANKSHAFT WITH THE CLUTCH DISASSEMBLY TOOL P N 10272 C see Fig 19 12mm ALLEN WRENCH 27mm...

Page 8: ...TARTER COUNTERSHAFT REMOVE STARTER COUNTERSHAFT COVER UNSCREW N 3 ALLEN SCREWS M6x25 see Fig 21 5mm ALLEN WRENCH T TYPE EXTRACT STARTER COUNTERSHAFT see Fig 22 10 REMOVE CARB INLET CONVEYOR UNSCREW N 4 ALLEN SCREWS M6x25 see Fig 23 5mm ALLEN WRENCH T TYPE REMOVE OUTER GASKET FROM CONVEYOR Fig 20 Fig 21 Fig 22 Fig 23 ...

Page 9: ...BY HALF TURN CROSS PATTERN DISASSEMBLY REMOVE NUTS see Fig 25 13mm HEXAGON RING WRENCH REMOVE WASHERS 12 REMOVE CYLINDER see Fig 26 REMOVE CYLINDER BASE GASKET 13 REMOVE PISTON REMOVE CIRCLIPS FROM PISTON see Fig 27 SCREWDRIVER WITH ROUND EDGES ATTENTION DO NOT SCRATCH PISTON AND CIRCLIP SEATS Fig 24 Fig 25 Fig 26 Fig 27 ...

Page 10: ...REMOVE PISTON REMOVE ROLLER CAGE 14 OPEN CRANKCASE UNSCREW N 10 ALLEN SCREWS M6x45 see Fig 29 5mm ALLEN WRENCH T TYPE OPEN CRANKCASE WITH A PLASTIC MALLET see Fig 30 PREVENT THE CRANKSHAFT FROM FALLING 15 REMOVE CRANKSHAFT AND BALANCE SHAFT see Fig 31 Fig 28 Fig 29 Fig 30 Fig 31 ...

Page 11: ... THE ATTACHED TABLE TO CHECK BEARING WEAR STATUS REMOVE BEARINGS FROM CRANKSHAFT WITH THE SPECIAL TOOL P N 10291 see Fig 33 REMOVE BEARING SPACERS 0 10 0 15 REMOVE BALANCE SHAFT OUTER BEARING GEAR SIDE UNSCREW THE BEARING RETAINING SCREW M5x10 see Fig 34 4mm ALLEN WRENCH T TYPE REMOVE BEARING WITH SPECIAL TOOL P N 10293 see Fig 35 Fig 32 Fig 33 Fig 34 Fig 35 ...

Page 12: ...VICE CENTER USING THE SPECIALLY DESIGNED TOOLS USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILLED PERSONNEL MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR DESCRIPTION P N CRANKSHAFT ASSEMBLY KIT 10110B C CRANKPIN BUSH INCLUDED IN 10110B C 10150A CRANKSHAFT DISASSEMBLY KIT INCLUDES 10100A C2 CRANKSHAFT SUPPORT 10100 CRANKSHAFT PLATE 10104A CRANKSHAFT INSERT 10106 CRANKPIN PUSHER 10107 2 1 CRANKSHA...

Page 13: ... EXCEEDS 0 01mm REPLACE CON ROD O O1 CENTESIMAL MICROMETER 21 50 0 001 BORE GAUGE WITH CHECK RING Ø26 AND Ø18 b CHECK STATUS OF CRANKPIN VISUAL CHECK REPLACE IF NECESSARY REPLACE AFTER 30 WORKING HRS c CHECK STATUS OF CAGE BIG END VISUAL CHECK REPLACE IF NECESSARY REPLACE AFTER 30 WORKING HRS d CHECK STATUS OF CRANKSHAFT HALVES CHECK BEARING SEATS IN DIFFERENT POINTS REFER TO THE ATTACHED TABLE TO...

Page 14: ...RTICALLY PRESS 5 MeT 2 PLACE THE CRANKSHAFT TOOL INTO THE ASSEMBLY TOOL 3 OIL CRANKPIN HOLE ON CRANKSHAFT HALF 4 PLACE CRANKPIN WITH CRANKPIN BUSH P N 10150A ON CRANKSHAFT HALF see Fig 1 5 BRING UPPER PLATE OF TOOL IN CONTACT WITH CRANKPIN see Fig 2 6 PROGRESSIVELY PRESS UNTIL CRANKPIN IS COMPLETELY DRIVEN IN see Fig 3 Fig 1 Fig 2 Fig 3 ...

Page 15: ... SHIM CON ROD WITH ROLLER CAGE SILVER SHIM see Fig 5 ATTENTION ROLLERS ARE FREE IN THE CAGE PREVENT THEM FROM FALLING WHEN INSERTING THE CAGE ON THE CRANKPIN 9 PLACE THE SECOND CRANKSHAFT IN THE SEAT OF THE COUNTERPLATE see Fig 6 10 BRING THE 2 PLATES CLOSE UNTIL THE TOOL IS HAND PRESSED see Fig 7 Fig 4 Fig 5 Fig 6 Fig 7 ...

Page 16: ... AXIAL PLAY OF THE CON ROD see Fig 9 IT MUST BE MIN 0 3mm MAX 0 7mm IF PLAY IS HIGHER OR LOWER REBUILD THE CRANKSHAFT AFTER ASSEMBLING THE CRANKSHAFT IT MUST BE ALIGNED OTHERWISE EXCESSIVE VIBRATIONS HARD STARTING OR POOR ACCELERATION WILL RESULT a PLACE THE CRANKSHAFT BETWEEN THE CENTERS WITH DIAL INDICATORS READING ON FRONT AND REAR BEARING JOURNALS see Fig 10 CENTERS WITH CENTESIMAL DIAL GAUGES...

Page 17: ...mm see drawing c ADJUST ALIGNMENT WITH A COPPER HAMMER IF NECESSARY see Fig 11 3 X30 125cc RL TaG ENGINE ASSEMBLY BEFORE REASSEMBLING WASH ALL PARTS WITH KEROSENE OPERATIONS PICTURES 1 INSTALLING BEARINGS PLACE THE CRANKCASE HALVES UNDER THE PRESS INSERT BEARING SHIMS AVAILABLE SIZES 0 10 0 15 0 20 see Fig 1 Fig 11 Fig 1 ...

Page 18: ...L INNER BALANCE SHAFT BEARING BEARING BALLS TO BE ON UPPER SIDE OIL BEARING BALLS BEFORE INSTALLATION OIL BEARINGS AND HALFCRANKCASE SEATS USE THE SPECIAL TOOL TO ASSEMBLE P N 10292 BEARINGS see Fig 4 INSTALL OUTER BALANCE SHAFT BEARING GEAR SIDE BEARING BALLS TO BE ON UPPER SIDE OIL BEARINGS AND HALFCRANKCASE SEATS USE SPECIAL TOOL P N 10293 TO INSERT BEARING see Fig 5 Fig 5 Fig 2 Fig 3 Fig 4 Fig...

Page 19: ...GINAL INSTALLATION see Fig 7 ASSEMBLE CRANKCASE HALVES N 10 ALLEN SCREWS M6x45 see Fig 8 CROSS PATTERN ASSEMBLY SEE ATTACHED DRAWING TORQUE AT 8 10 Nm 70 90 in lb 5mm ALLEN WRENCH T TYPE ATTENTION AS FIRST STEP ASSEMBLE CRANKCASE WITH 4 SCREWS AND CHECK CRANKSHAFT AXIAL PLAY TO BE 0 20 0 05mm IF PLAY IS LOWER OR HIGHER DISASSEMBLE CRANKCASE EXTRACT BEARINGS AND USE DIFFERENT STEEL SHIMS 0 10 0 15 ...

Page 20: ...e Fig 10 OIL CRANKSHAFT AND BEARING BALLS SEATS BEFORE ASSEMBLING see Fig 11 INSERT THE CRANKSHAFT AND BALANCE SHAFT CLOSE THE CRANKCASE HALVES see Fig 12 3 INSTALLING SEALS APPLY SPECIAL LUBRICANT ON SEAL LIPS see Fig 13 ATTENTION WHEN INSTALLING NEW SEALS TURNING THE CRANKSHAFT SHOULD RESULT MORE DIFFICULT BUT THIS IS NORMAL Fig 13 Fig 10 Fig 11 Fig 12 ...

Page 21: ...E SPECIAL TOOL P N 10296 see Fig 16 MARK ON SEAL TO BE OUTSIDE ATTENTION OIL SEALS MUST ALWAYS BE REPLACED WHEN DISASSEMBLED 4 INSTALLING GEARS CHECK THE GOOD STATUS OF TEETH ON THE GEAR INSTALL GEAR ON THE BALANCE SHAFT LETTER C TO BE VISIBLE BEING CAREFUL TO ALIGN THE REFERENCE NOTCHES ON THE INTERNAL TEETH WITH THE HELP OF A PLASTIC HAMMER see Fig 17 ATTENTION IF GEARS ARE NOT PROPERLY INSTALLE...

Page 22: ...CRANKSHAFT AND BALANCE SHAFT see Fig 19 PLIERS FOR RETAINING RINGS FOLLOW THE RECOMMENDATIONS AS PER ATTACHMENT NOTE IN THE ENGINES MNUFACTURED AFTER SEPTEMBER 05 THE FIXING OF THE GEAR ON THE CRANKSHAFT IS MADE BY A SPACER WITH AN OR WHICH IS PUSHED AGAINST GEAR BY THE IGNITION ROTOR 5 INSTALLING THE STARTER PLACE STARTER IN THE CRANKCASE SEAT see Fig 20 OIL O RING BEFORE INSERTING CHECK THAT THE...

Page 23: ...INT WRENCH 11mm POUR 40cc SAE 30 OIL IN THE GEAR BOX see Fig 24 NOTE IF QUANTITY IS CORRECT YOU WILL NOTE OIL SLIGHTLY OVERFLOWING FROM OIL HOLE PLUG INSTALL OIL DRAIN PLUG TORQUE AT 12 15 Nm 105 130 in lb 12 POINT WRENCH 14mm REMOVE BREATHER 8 INSTALLING THE PISTON CHECK STATUS OF CAGE IT IS RECOMMENDED TO REPLACE IT AFTER 30 HRS AND ALWAYS WHEN OVERHAULING THE ENGINE CHECK STATUS OF PISTON PIN R...

Page 24: ...RED AT 17 5mm FROM BOTTOM see attachment ALWAYS REPLACE PISTON AND PISTON RING INSERT CAGE IN THE CON ROD HOLE LITTLE END AND PISTON PIN WITH SPECIAL PISTON PIN PUNCH P N 10200 see Fig 27 MAKE SURE THAT ARROW ON THE TOP OF PISTON IS TURNED TOWARDS EXHAUST AS GENERAL RULE THE PISTON PIN MUST BE INTRODUCED BY HAND AND FORCED IN THE HOLE IF THE PISTON PIN IS LOOSE IN SEAT REPLACE IT WITH A PISTON PIN...

Page 25: ...F CYILINDER ON EXTERNAL OF CYLINDER ON TIE RODS 10 ASSEMBLING THE CYLINDER HEAD CLEAN COMBUSTION CHAMBER FROM DEPOSITS ATTENTION DO NOT SCRATCH COMBUSTION CHAMBER INSTALL HEAD see Fig 32 N 4 SCREWS M8 WITH WASHERS CROSS PATTERN ASSEMBLY TORQUE AT 18 22 Nm 160 190 in lb TORQUE WRENCH WITH 13mm BUSH 11 INSTALLING THE IGNITION INSERT KEY ON SHAFT see Fig 33 Fig 30 Fig 31 Fig 32 Fig 33 ...

Page 26: ...E AT 20 26 Nm 175 230 in lb see Fig 35 17mm SOCKET WRENCH INSTALL STATOR N 4 ALLEN SCREWS M5x25 see Fig 36 TORQUE AT 5 6 Nm 45 50 in lb 4mm ALLEN WRENCH T TYPE REMOVE PISTON FITTING FROM HEAD 12 INSTALL STARTER COUNTERSHAFT GREASE BOTH COUNTERSHAFT ENDS AND INSERT COUNTERSHAFT IN CRANKCASE SEAT see Fig 37 Fig 34 Fig 35 Fig 36 Fig 37 ...

Page 27: ...ODY AND THE CLUTCH DRUM 13 ASSEMBLING THE CLUTCH INSTALL STARTER RING ON CLUTCH BODY BY MATCHNG THE 3 HOLES AND THE DRAGGING PIN see Fig 39 INSTALL N 3 SCREWS M6x12 APPLY LOCTITE ON THE THREADS Loctite 243 TORQUE AT 9 11 Nm 80 100 in lb see Fig 40 10mm SOCKET TYPE TORQUE METER ATTENTION MAKE SURE TO ALWAYS INSTALL THE Ø 7mm DRAGGING PIN AS OTHERWISE THE EVENTUAL KICKBACKS COULD BREAK THE SCREWS Fi...

Page 28: ... RING FIXING NUT USE CLUTCH WRENCH P N 10270 TORQUE AT 100 110 Nm 885 970 in lb see Fig 43 30mm SOCKET TYPE TORQUE METER ATTENTION TURN COUNTERCLOCKWISE AS NUT HAS LEFT THREAD NOTE DO NOT USE THE PISTON FITTING TOOL TO PREVENT THE SHAFT FROM TURNING INSTALL INTERNAL WASHER see Fig 44 ATTENTION INSTALL WASHER WITH BEVEL TOWARDS SHAFT Fig 41 Fig 42 Fig 43 Fig 44 ...

Page 29: ...L WASHER WITH BEVEL TOWARDS SHAFT INSTALL PISTON FITTING P N 10271 TO PREVENT SHAFT FROM TURNING AND TIGHTEN THE M10 NUT FIXING THE DRUM see Fig 47 TORQUE AT 30 40 Nm 265 350 in lb 12 POINT WRENCH 17mm REMOVE THE PISTON FITTING INSTALL CLUTCH COVER N 3 ALLEN SCREWS M6x25 see Fig 48 TORQUE AT 8 10 Nm 70 90 in lb 5mm ALLEN WRENCH T TYPE Fig 45 Fig 46 Fig 47 Fig 48 ...

Page 30: ... DO NOT MATCH PERFECTLY REPLACE THEM REMOVE N 8 SCREWS AND PLACE REED PETALS WITH CUT ON THE BOTTOM TO BE TOWARDS RIGHT SIDE INSTALL THE EXTERNAL GASKET BE SURE THAT THE HOLE ON THE GASKET MATCHES WITH THE HOLE ON THE INLET MANIFOLD INSTALL THE INLET MANIFOLD AND CARBURETOR GASKET N 4 ALLEN SCREWS M6X25 see Fig 51 TORQUE AT 8 10 Nm 70 90 in lb 5mm ALLEN WRENCH T TYPE 15 INSTALLING THE EXHAUST HEAD...

Page 31: ...MAN 044 A 29 ...

Page 32: ...MAN 044 A 30 CROSS PATTERN LOCKING ORDER ON CRANKCASE ...

Page 33: ...ween A and B on used conrod 0 01mm ATTENTION Play between piston and liner must be 0 11 0 12mm if play is higher than 0 14mm replace piston Pistons are measured at 17 5mm from bottom Size of liner to be matched with piston is marked on top of piston with a green or red dot or with letter V or R If the size on piston top is marked with a green dot or letter V add 0 01mm to size marked on the piston...

Page 34: ...MAN 044 A 32 ...

Page 35: ... BE READ ON THE SURFACE AND ALIGN THE MARKED GEAR TOOTH SPACE 3 WITH THE MARKED TOOTH ON THE CRANKSHAFT 4 FIT THE TWO GEAR TEETH ALIGNING THE NOTCHES ON TEETH 5 AND 6 3 4 5 6 4 CHECK THAT THE GEAR SURFACES ARE ON THE SAME PLANE IF THERE IS A STEP BETWEEN THE TWO GEARS REPEAT THE INSTALLATION 5 BEFORE INSTALLING THE RETAINING RINGS CHECK THE POSITION OF GEARS AND THE ALIGNMENT OF ALL REFERENCE NOTC...

Page 36: ...BEARING ASSEMBLY TOOL INTERNAL BALANCE SHAFT BEARING ASSY DISASSY TOOL OIL SEAL ASSEMBLY TOOL without crankshaft OIL SEAL ASSEMBLY TOOL with installed crankshaft GEAR COVER OIL SEAL ASSEMBLY TOOL 10291 10293 10290 10292 10295 10295A 10296 ENGINE FIXING TOOL ON BENCH VICE see attached drawing STANDARD TOOLS ALLEN WRENCH T TYPE 4mm ALLEN WRENCH T TYPE ALLEN WRENCH 5mm 12mm HEXAGON RING WRENCH T TYPE...

Page 37: ...LANCE SHAFT EXTERNAL BEARING SEAT MICROMETER 0 25 1 100 MIN Ø24 96 BALANCE SHAFT INTERNAL BEARING SEAT MICROMETER 0 25 1 100 MIN Ø14 95 CRANKSHAFT BEARINGS 1 100 BORE GAUGE WITH CHECK RING Ø30 MAX Ø30 03 BALANCE SHAFT EXTERNAL BEARING 1 100 BORE GAUGE WITH CHECK RING Ø25 MAX Ø25 03 BALANCE SHAFT INTERNAL BEARING BORE GAUGE 1 100 WITH CHECK RING Ø15 MAX Ø15 03 ATTENTION THE MEASURED VALUE ON THE BE...

Page 38: ...MAN 044 A 36 FIXING TOOL ON VICE BENCH ...

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